Cross Reference to Related Applications

[0001]This application claims priority to U.S. Provisional Application No. 62/585,095, filed November 13, 2017, the subject matter of which is hereby incorporated by reference in its entirety.

Background

[0002] Insulation piercing connectors may be used to attach sensing conductors, such as voltage detection lines, to a power cable. Some voltage detection devices may use dual independent electrical connections to each phase of a power cable to perform voltage detection. Voltage detection devices are typically mounted inside of a control panel before a first termination. Mounting a voltage detection device within the control panel provides for limited access and space.

Summary

[0003] The present invention provides for a voltage detection that utilizes two independent electrical connections to a power cable for voltage detection through an insulation piercing connector.

Brief Description of the Drawings

[0004] The following detailed description references the drawings, wherein:

[0005] FIG. 1 is a trimetric view of an example insulation piercing connector;

[0006] FIG. 2 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 1 ;

[0007] FIG. 3 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 1 ; [0008] FIG. 4 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 1 ;

[0009] FIG. 5 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 1 ;

[0010] FIG. 6 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 1 ;

[0011] FIG. 7 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 1 ;

[0012] FIG. 8 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 1 ;

[0013] FIG. 9 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 1 ;

[0014] FIG. 10 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 1 along with voltage detection conductors;

[0015] FIG. 1 1 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 1 along with voltage detection conductors;

[0016] FIG. 12 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 1 along with voltage detection conductors;

[0017] FIG. 13 is a trimetric view of the example insulation piercing connector shown in FIG. 1 along with voltage detection conductors;

[0018] FIG. 14 is a trimetric view of the example insulation piercing connector shown in FIG. 1 along with voltage detection conductors; [0019] FIG. 15 is a trimetric view of the example insulation piercing connector shown in FIG. 1 attached to voltage detection conductors;

[0020] FIG. 6 is a trimetric view of the example insulation piercing connector shown in FIG. 1 attached to voltage detection conductors;

[0021] FIG. 17 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 1 attached to voltage detection conductors;

[0022] FIG. 18 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 1 attached to voltage detection conductors along with a power cable;

[0023] FIG. 19A is a trimetric view of the example insulation piercing connector shown in FIG. 1 attached to voltage detection conductors along with a power cable;

[0024] FIG. 19B is a cross-sectional view along line 19B-19B in FIG. 19A of the example insulation piercing connector shown in FIG. 1 attached to voltage detection conductors along with a power cable;

[0025] FIG. 20A is a trimetric view of the example insulation piercing connector shown in FIG. 1 attached to voltage detection conductors and a power cable;

[0026] FIG. 20B is a cross-sectional view along line 20B-20B in FIG. 20A of the example insulation piercing connector shown in FIG. 1 attached to voltage detection conductors and a power cable;

[0027] FIG. 21 is a trimetric view of a second example insulation piercing connector;

[0028] FIG. 22 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 21 ;

[0029] FIG. 23 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 21 ; [0030] FIG. 24 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 21 ;

[0031] FIG. 25 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 21 ;

[0032] FIG. 26 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 21 ;

[0033] FIG. 27 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 21 ;

[0034] FIG. 28 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 21 ;

[0035] FIG. 29 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 21 ;

[0036] FIG. 30 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 21 along with voltage detection conductors;

[0037] FIG. 31 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 21 along with voltage detection conductors;

[0038] FIG. 32 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 21 along with voltage detection conductors;

[0039] FIG. 33 is a trimetric view of the example insulation piercing connector shown in FIG. 21 along with voltage detection conductors;

[0040] FIG. 34 is a trimetric view of the example insulation piercing connector shown in FIG. 21 along with voltage detection conductors; [0041] FIG. 35 is a trimetric view of the example insulation piercing connector shown in FIG. 21 attached to voltage detection conductors;

[0042] FIG. 36 is a trimetric view of the example insulation piercing connector shown in FIG. 21 attached to voltage detection conductors;

[0043] FIG. 37 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 21 attached to voltage detection conductors;

[0044] FIG. 38 is an exploded trimetric view of the example insulation piercing connector shown in FIG. 21 attached to voltage detection conductors along with a power cable;

[0045] FIG. 39A is a trimetric view of the example insulation piercing connector shown in FIG. 21 attached to voltage detection conductors along with a power cable;

[0046] F!G. 39B is a cross-sectional view along line 39B-39B in FIG. 39A of the example insulation piercing connector shown in FIG. 21 attached to voltage detection conductors along with a power cable;

[0047] FIG. 40A is a trimetric view of the example insulation piercing connector shown in

FIG. 21 attached to voltage detection conductors and a power cable; and

[0048] FIG. 40B is a cross-sectional view along line 40B-40B in FIG. 40A of the example insulation piercing connector shown in FIG. 21 attached to voltage detection conductors and a power cable.

Detailed Description

[0049] The disclosed insulation piercing connector solves or improves upon one or more of the above noted and/or other problems and disadvantages with voltage detection devices and systems. The disclosed insulation piercing connector provides for a tandem system for sensing voltage in a compact configuration connectable in or out of a control panel. These and other objects, features, and advantages of the present disclosure will become apparent to those having ordinary skill in the art upon reading this disclosure.

[0050] Reference will now be made to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar parts. It is to be expressly understood, however, that the drawings are for illustration and description purposes only. While several examples are described in this document, modifications, adaptations, and other implementations are possible. Accordingly, the following detailed description does not limit the disclosed examples. Instead, the proper scope of the disclosed examples may be defined by the appended claims.

[0051] FIGs. 1 -18, 19A, 19B, 20A, and 20B are illustrations of an example insulation piercing connector 100. In some implementations, insulation piercing connector 100 may be used to provide a connection between voltage detection conductors 130a, 130b and a power cable 132 (FIGs. 10-20B). The connection may provide dual independent electrical connections between a voltage detection device (not shown) and power cable 132.

[0052] Insulation piercing connector 100 may include a top half 101 , a bottom half 102, and a blade seal 103 held together by a fastener 104, such as a screw, bolt, or other types of fasteners. Top half 101 and bottom half 102 may be made of various insulating materials, such as various types of polymers/plastics. In one example, top half 101 and bottom half 102 may be made of a glass-filed nylon polymer. Blade seal 103 may be made of a rubber or elastomer. Fastener 104 may be made of an insulating material as well, or may be made of various metals.

[0053] A washer 107 (such as a ring washer, spring washer, or other types known in the art) may be positioned between the head of fastener 104 and top half 101 to evenly distribute the compression force applied by fastener 104. The threaded shaft of fastener 104 may be placed through hole 108 in top half 10 , hole 1 1 in blade seal 103, and into a post 1 14. Post 1 14 may include a hole having threads therein, where the threads may be formed as integral part of post 1 14 or may be a metal or plastic threaded insert that is inserted into the hole in post 1 14. The threads of the threaded shaft of fastener 104 may engage with the threads in the hole in post 14 to compress top half 101 , bottom half 102, and blade seal 103 together.

[0054] Insulation piercing assembly 133 may provide the electrical connection between power cable 132 (FIGs. 18-20B) and voltage detection conductors 130a, 130b. Insulation piercing assembly 133 may be made up of components formed of a conductive material such as copper. As shown in the exploded view of insulation piercing assembly 133 in FIG. 2, insulation piercing assembly 133 may include piercing blades 1 17a, 1 17b respectively attached to terminal housings 1 15a, 1 15b via fasteners (e.g., screws) 1 18a, 1 18b. The ends of voltage detection conductors 130a, 130b may be respectively inserted into terminal housings 1 15a, 1 15b and secured in place by fasteners 1 16a, 1 16b.

[0055] Insulation piercing assembly 133 may be positioned within bottom half 102 of insulation piercing connector 100. For example, insulation piercing assembly 133 may sit in recesses 1 19a, 1 19b of bottom half 102, with the teeth of piercing blades 1 17a, 1 17b respectively sitting in grooves 134a, 134b. In alternative implementations, insulation piercing assembly 133 may sit in recesses in top half 101 .

[0056] Blade seal 103 may be positioned on top of bottom half 102 and insulation piercing assembly 133. Blade seal 103 may include a U-shaped sidewall 109 that partially overlaps a portion of top half 101 and bottom half 102. Blade seal 103 may also include notches 123a-c that may be positioned in holes 121 a-c to ensure that blade seal 103 is properly aligned on top of bottom half 102 and insulation piercing assembly 133. Rubberized insulating seals 1 12a, 1 12b may respectively cover the teeth of piercing blades 1 17a, 1 17b prior to insulation piercing connector 100 being compressed around power cable 132, at which point the teeth of piercing blades 1 17a, 117b penetrate insulating seals 1 12a, 1 12b. Insulating seals 1 12a, 1 12b prevent voltage leakage from the connection between piercing blades 1 17a, 1 17b and power cable 132 by forming a seal around the portion of the insulating layer penetrated by piercing blades 117a, 1 17b. The teeth of piercing blades 1 17a, 1 17b may be positioned respectfully within grooves 127a, 127b of insulating seals 1 12a, 1 12b.

[0057] Top half 101 may be placed on top of blade seal 103. Top half 101 and bottom half 102 may respectively have first round ends 124 and 120. When top half 101 , bottom half 102, and blade seal 103 are all assembled, round ends 124 and 120 may form a recess 105 in which power cable 132 may be positioned.

[0058] As depicted in FIGs. 18-20B, in operation, to attach insulation piercing clamp 100 to power cable 132, fastener 104 may be loosened to a point where there is enough space between top half 101 and bottom half 102 to insert power cable 132 into recess 105. Fastener 104 may then be tightened so that a compression force is applied to top half 101 and bottom half 102. The compression force causes the teeth of piercing blades 1 17a, 1 17b to respectively pierce through insulating seals 1 12a, 1 12b, exposing them to the insulation layer around power cable 32. As top half 101 and bottom half 102 compress together further, the teeth of piercing blades 1 17a, 1 17b may pierce through the insulation layer to the core of power cable 132 (which may be solid or stranded), thereby providing dual independent electrical connections to power cable 132. Insulating seals 1 12a, 1 12b prevent voltage leakage at the connection points.

[0059] As depicted in FIGs. 13-16, to attach voltage detection conductors 130a, 130b to terminal housings 1 15a, 1 15b, an installer may insert the conductive ends of voltage detection conductors 130a, 130b respectively into openings 128a, 128b, and into holes 129a, 129b of terminal housings 1 15a, 1 15b. Ferrules 131 a, 131 b may be installed over the conductive ends of voltage detection conductors 130a, 130b to provide improved electrical connection with terminal housings 115a, 15b.

[0060] The installer may view voltage detection conductors 130a, 130b through viewing holes to visually verify that voltage detection conductors 130a, 30b (or ferrules 131 a, 131 b, if installed) have been fully inserted into terminal housings 1 15a, 1 15b. For example, top half 101 may include recesses 106a, 106b that are subdivided into access holes 125a, 125b and viewing holes 126a, 126b; blade seal 103 may also include viewing holes 1 13a, 1 13b that align with viewing holes 126a, 126b of top half 10 ; and terminal housings 1 15a, 1 15b may include viewing holes 122a, 122b that align with viewing holes 1 13a, 1 13b of blade seal 103 and viewing holes 126a, 126b of top half 101 . The installer may view voltage detection conductors 130a, 130b through the series of viewing holes in top half 101 and blade seal 103 as they are inserted into terminal housings 1 15a, 115b, and may secure voltage detection conductors 130a, 130b in terminal housings 1 15a, 1 15b view fasteners 1 16a, 1 16b once the installer has verified that voltage detection conductors 130a, 130b have been fully inserted into terminal housings 1 15a, 1 15b.

[0061] The installer may secure voltage detection conductors 30a, 130b in terminal housings 1 15a, 1 15b by inserting a fastening tool, such as a screw driver through access holes 125a, 125b in top half 101 , and access holes 10a, 1 10b in blade seal 103, to tighten fasteners 116a, 1 16b.

[0062] FIGs. 21 -38, 39A, 39B, 40A, and 40B are illustrations of a second example insulation piercing connector 200. In some implementations, insulation piercing connector 200 may be used to provide a connection between voltage detection conductors 230a, 230b and a power cable 232 (FIGs. 30-40B). The connection may provide dual independent electrical connections between a voltage detection device (not shown) and power cable 232.

[0063] Insulation piercing connector 200 may include a top half 201 , a bottom half 202, and a blade seal 203 held together by a fastener 204, such as a screw, bolt, or other types of fasteners. Top half 201 , bottom half 202, and blade seal 203 may be made of various insulating materials, such as various types of polymers/plastics. In one example, top half 201 , bottom half 202, and blade seal 203 may be made of a glass-filed nylon polymer. Blade seal 203 may be made of a rubber or elastomer. Fastener 204 may be made of an insulating material as well, or may be made of various metals.

[0064] A washer 207 (such as a ring washer, spring washer, or other types known in the art) may be positioned between the head of fastener 204 and top half 201 to evenly distribute the compression force applied by fastener 204. The threaded shaft of fastener 204 may be placed through hole 208 in top half 201 , hole 21 1 in blade seal 203, and into a post 214. Post 214 may include a hole having threads therein, where the threads may be formed as integral part of post 214 or may be a metal or plastic threaded insert that is inserted into the hole in post 214. The threads of the threaded shaft of fastener 204 may engage with the threads in the hole in post 214 to compress top half 201 , bottom half 202, and blade seal 203 together.

[0065] Insulation piercing assembly 233 may provide the electrical connection between power cable 232 and voltage detection conductors 230a, 230b. Insulation piercing assembly 233 may be made up of components formed of a conductive material such as copper. As shown in the exploded view of insulation piercing assembly 233 in FIG. 2, insulation piercing assembly 233 may include piercing blades 217a, 217b. The tangs of insulation piercing blades 217a, 217b may be respectively inserted into holes 229a, 229b of terminal housings 215a, 215b along with the ends of voltage detection conductors 230a, 230b. Voltage detection conductors 230a, 230b may be positioned underneath the tangs of piercing blades 217a, 217b. Fasteners (e.g., screws) 216a, 216b may be tightened to compress the tangs of piercing blades 217a, 217b and the ends of voltage detection conductors 230a, 230b against the bottom of terminal housings 215a, 215b in order to secure piercing blades 217a, 217b and voltage detection conductors 230a, 230b in place.

[0066] Insulation piercing assembly 233 may be positioned within bottom half 102 of insulation piercing connector 200. For example, insulation piercing assembly 233 may sit in recesses 219a, 219b of bottom half 202, with the teeth of piercing blades 217a, 217b respectively sitting in grooves 234a, 234b. In alternative implementations, insulation piercing assembly 233 may sit in recesses in top half 201 .

[0067] Blade seal 203 may be positioned on top of bottom half 202 and insulation piercing assembly 233. Blade seal 203 may include a U-shaped sidewall 209 that partially overlaps a portion of top half 201 and bottom half 202. Blade seal 203 may also include notches 223a-c that may be positioned in holes 221 a-c to ensure that blade seal 203 is properly aligned on top of bottom half 202 and insulation piercing assembly 233. Rubberized insulating seals 212a, 212b may respectively cover the teeth of piercing blades 217a, 217b prior to insulation piercing connector 200 being compressed around power cable 232, at which point the teeth of piercing blades 217a, 217b penetrate insulating seals 212a, 212b. Insulating seals 212a, 212b prevent voltage leakage from the connection between piercing blades 217a, 217b and power cable 232 by forming a seal around the portion of the insulating layer penetrated by piercing blades 217a, 217b. The teeth of piercing blades 217a, 217b may be positioned respectfully within grooves 227a, 227b of insulating seals 212a, 212b.

[0068] Top half 201 may be placed on top of blade seal 203. Top half 201 and bottom half 202 may respectively have first round ends 224 and 220. When top half 201 , bottom half 202, and blade seal 203 are all assembled, round ends 224 and 220 may form a recess 205 in which power cable 232 may be positioned.

[0069] As depicted in FIGs. 39A-40B, in operation, to attach insulation piercing clamp 200 to power cable 232, fastener 204 may be loosened to a point where there is enough space between top half 201 and bottom half 202 to insert power cable 232 into recess 205. Fastener 204 may then be tightened so that a compression force is applied to top half 201 and bottom half 202. The compression force causes the teeth of piercing blades 217a, 217b to respectively pierce through insulating seals 212a, 212b, exposing them to the insulation layer around power cable 232. As top half 201 and bottom half 202 compress together further, the teeth of piercing blades 217a, 217b may pierce through the insulation layer to the core of power cable 232 (which may be solid or stranded), thereby providing dual independent electrical connections to power cable 232. Insulating seals 212a, 212b prevent voltage leakage at the connection points.

[0070] As depicted in Figs. 33-36, to attach voltage detection conductors 230a, 230b to terminal housings 215a, 215b, an installer may insert the conductive ends of voltage detection conductors 230a, 230b respectively into openings 228a, 228b of bottom half 202, and into holes 229a, 229b of terminal housings 215a, 215b under the tangs of piercing blades 217a, 217b. Ferrules 231 a, 231 b may be installed over the conductive ends of voltage detection conductors 230a, 230b to provide improved electrical connection with terminal housings 215a, 215b. The installer may secure voltage detection conductors 230a, 230b in terminal housings 215a, 215b by inserting a fastening tool, such as a screw driver through access holes 225a, 225b in top half 201 , and access holes 210a, 210b in blade seal 203, to tighten fasteners 216a, 216b.

[0071] Note that while the present disclosure includes several embodiments, these embodiments are non-limiting, and there are alterations, permutations, and equivalents, which fall within the scope of this invention. Additionally, the described embodiments should not be interpreted as mutually exclusive, and should instead be understood as potentially combinable if such combinations are permissive. It should also be noted that there are many alternative ways of implementing the embodiments of the present disclosure. It is therefore intended that claims that may follow be interpreted as including all such alterations, permutations, and equivalents as fail within the true spirit and scope of the present disclosure.